ete IR1759-MK5-AT3130-EDCont User manual

IR1759-MK5-AT3130-EDCONT MINIRAY
TE Connectivity - Aerospace, Defence & Marine /// Application Tooling
Page 1 of 36
Operation and Maintenance Manua – Issue 3
Mini-ray Too IR1759-MK5-AT3130-EDCont
PCN.CV3948-000
Language: (origina version Eng ish)

IR1759-MK5-AT3130-EDCONT MINIRAY
TE Connectivity - Aerospace, Defence & Marine /// Application Tooling
Page 2 of 36
 IR-1759 MINIRAY Hand Tool and Controllers, SolderSleeve
®
, MiniSeal
®
,
SolderTacts
®
, and Ther ofit
®
heat-shrinkable products are trade arks of TE
Connectivity.

 All of the infor ation in this anual, including illustrations, is believed to be reliable.
Users, however, should independently evaluate the suitability of each product for
their application.
 TE Connectivity /Tyco Electronics/Rayche ake no warranties as to the accuracy
or co pleteness of the infor ation and disclai any liability regarding its use.
 TE Connectivity /Tyco Electronics/Rayche only obligations are those in the
Standard Ter s and Conditions of Sale for this product and in no case will TE
Connectivity/Tyco Electronics/Rayche be liable for any incidental, indirect or
consequential da ages arising fro the sale, resale, use or isuse of the product.
 TE Connectivity/Tyco/Rayche Specifications are subject to change without notice.
In addition TE Connectivity /Tyco Electronics reserve the right to ake changes in
aterials or processing, without notification to Buyer, which do not affect co pliance
with any applicable specification.
 TE Connectivity No part of this anual ay be reproduced or trans itted in any
for or by any eans, electronic or echanical, including photocopying, or recorded
by any infor ation storage or retrieval syste , without written per ission fro
TE/Tyco.
 This product ust not be disposed of as unicipal waste.
 TE produces IR1759-MK5-AT3130-EDCONT MINIRAY Hand Tool and Controllers in
confor ity with RoHS 2015/863/EU.UL499, UL Listing: E62371. The tool has been
anufactured to Low Voltage Directive 2014/35/EU,
 Infor ation on the occurrence and location of substances subject to RoHS
guidelines can be found at the following website:
http://www.te.co /custo ersupport/productco pliance/
 It is intended for use by trained, qualified operating and aintenance personnel and
assu es the equip ent has been supplied co plete and is un odified
Genera

IR1759-MK5-AT3130-EDCONT MINIRAY
TE Connectivity - Aerospace, Defence & Marine /// Application Tooling
Page 3 of 36
ED-7-CONT-230/110V MK5
 Dimensions: 160x120x250
 Weight:: 6.2 kg
 Vo ts: 230/110 50/60 Hz1
 Vo tage amp: 23.5 /24 v AC.
 Connection 3 pin IEC
 Fuses 4AT Mains -16AT to Gun
Mini Ray hand too IR1759MK5
 Weight::1.1 kg
 Noise: 51db
 Cab e ength 3 eters
 Vo ts: 23.5 /24 v AC.
 Watts 250
 Lamp Type Tungsten
 Connection Type, 6 pin connector
 Cord Length 3.1 M
App ication
 Max Product diameter (mm 6)
 Max product ength (mm 25)
 Max product ength with c amps (mm 19)
Technica Specifications

IR1759-MK5-AT3130-EDCONT MINIRAY
TE Connectivity - Aerospace, Defence & Marine /// Application Tooling
Page 4 of 36
Contents: page
1 Revision history................................................................................................................... 5
2 Introduction.......................................................................................................................... 6
2.1 How to use the manua ………………………………………………………………………….. 6
2.2 System description……………………………………………………………………………….. 7
3 Genera notes on safety ..................................................................................................... 11
3.1 Important safety instructions ............................................................................................ 11
3.2 E ectrica safety................................................................................................................... 12
3.3 Hot surfaces ........................................................................................................................ 12
3.4 Eye protection and Optica Radiation Hazard .................................................................. 13
3.5 Genera instructions...........................................................................................................13
3.6 Standard e ectrica rating abe ......................................................................................... 14
4 Insta ation ........................................................................................................................... 15
4.1 Insta ation and Set - up ..................................................................................................... 15
4.2 Changing the Aperture ....................................................................................................... 17
5 Operation ............................................................................................................................. 22
6 Maintenance ........................................................................................................................ 23
6.1 Genera Maintenance and service ..................................................................................... 23
6.2 Gun Maintenance............................................................................................................... 24
6.3 Lamp and fi ter rep acement............................................................................................. 25
6.4 Rep acing trigger PCB....................................................................................................... 27
7 Spares /Ordering information............................................................................................28
8 E ectrica Wiring diagrams……………….......................................................................... 32
8.3 Fau t Finding……………………………………………………………………………………… 34
9 TE Connectivity contacts.................................................................................................. 35
10 AD-1318-9 Ho ding Fixture……………………………………………………………………... 36

IR1759-MK5-AT3130-EDCONT MINIRAY
TE Connectivity - Aerospace, Defence & Marine /// Application Tooling
Page 5 of 36
1. Revision history
Rev. Date Description Name
Issue 1 Jan 2014 New Tool UL approved
Issue 2 Feb 2015 Add section
Issue 3 May 2019 Updated infor ation

IR1759-MK5-AT3130-EDCONT MINIRAY
TE Connectivity - Aerospace, Defence & Marine /// Application Tooling
Page 6 of 36
2. Introduction
If a local language translation of this anual is required please contact local TE /Tyco
Electronics Technical Service
 As with all electrical equip ent, the IR1759-MK5 MINIRAY Hand Tool and Controllers ust
be operated properly. It is intended for use by trained operating and aintenance staff and
assu es the equip ent has been supplied co plete and is un odified.
 Carefully read and observe all the instructions and warnings in this anual.
 Incorrect use of the IR1759-MK5 MINIRAY Hand Tool can cause serious injury. This
equip ent ust be operated and aintained only by fully trained and qualified personnel.
 Failure to follow the anufacturer’s instructions ay void the warranty of this equip ent.
 The IR1759-MK5 MINIRAY Hand Tool and Controllers ust be operated in accordance with
safe working practices and local safety codes and regulations.
 Do not use the IR1759-MK5 MINIRAY Hand Tool and Controllers for any purpose other than
its intended function.
 The IR1759-MK5 MINIRAY Hand Tool control odule carries International Protection (IP)
Code of IP12.5 and the Controller odules carries an International Protection (IP) Code of
IP1.1.Never expose the IR1759-MK5 MINIRAY Hand Tool and Controllers to water and
oisture.
This anual gives infor ation regarding the safe operation and aintenance of the equip ent.
Before operating or aintaining the equip ent you ust read and understand the following sections:
3. Safety Section – E ectrica and Hot Surfaces.
4. Insta ation and Set-Up.
2.1 About this Manua
2.2 How to Use
this Manua

IR1759-MK5-AT3130-EDCONT MINIRAY
TE Connectivity - Aerospace, Defence & Marine /// Application Tooling
Page 7 of 36
IR1759-MK5 MINIRAY Hand Too
 The IR1759-MK5 MINIRAY Hand Tool and Controllers co bine to for a lightweight, ediu
duty syste for low volu e bench production and in-site application equip ent for TE’s
SolderSleeve
®
, MiniSeal
®
, SolderTacts
®
, and Ther ofit
®
heat-shrinkable devices ter inations
 The IR1759-MK5 MINIRAY Hand Tool uses infra-red energy derived fro a tungsten halogen
la p as its radiant heat source. The tool is nor ally used with an external reflector to focus
the heat fro the la p unifor ly around the circu ference of the work-piece, concentrating
heat energy within the work area of the front reflector. The internal reflector asse bly
contains an optical filter which reduces the a ount of visible light and ultraviolet (UV)
radiation e itted. An optical filter between the la p and the work area reduces glare fro the
la p, allowing the operator to observe the heating process and reducing eye strain to the
operator.
 The Mini-ray Hand-tool is supplied with cable and connector ready to connect to this specific
UL approved ED-7-CONT Controllers.
 ON/OFF Trigger Control. The function of the Mini-ray Hand-tool trigger is to switch power to
la p when required. The switch provides for continuous operation of up to 70 sec (ON) and 2
sec (OFF) after which 70 seconds continuous operation again is possible. It is possible to
‘pulse’ the tool to finish an inco plete installation, provided the trigger is pressed for 2
seconds.
 The IR1759-MK5 MINIRAY Hand Tool contains a cooling fan inside the Hand Tool to aintain
acceptable te peratures for the internal co ponents as well as for keeping external surfaces
cool and to allow for long-duration heating. Since the front reflector is outside the cooling air
strea , it ay get hot during long heating cycles
 The tool is also equipped with a ther ostatic switch to protect it fro overheating.
Overheating activates the switch, which disconnects the heat la p te porarily.
2.3 System Description
COOLING FAN

IR1759-MK5-AT3130-EDCONT MINIRAY
TE Connectivity - Aerospace, Defence & Marine /// Application Tooling
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2.3 System Description continued The IR1759-MK5 MINIRAY Hand Too
Fig 3
MINIRAY Hand Too Connector –
 The input connector is a 6-pin ‘fe ale’ plug at the end of the supply lead. The plug is fitted
with a locking ring and is connected to the output socket on the controller.
 The Mini-ray Hand-tool has one connector and one operator control.
System Connections and Contro s – ED-7-CONT-230/110V MK5
 The Controller is used to provide an electrical supply to the Mini-ray Hand-tool.
 The Controller and co ponents are housed in sturdy etal cases, designed to operate on a
bench or table.
 The Controller operates as a si ple switched supply for the Mini-ray Hand-tool and is turned
on and off by the trigger on the Hand-tool. In this ode the Controller always provides full
power to the Hand-tool for as long as the trigger is depressed.
 Controller ED-7-CONT-230/110V MK5 provides a controlled and regulated voltage to the
la p in the Mini-ray hand tool while the trigger is depressed. This controlled voltage ensures
that the la p will not see ore than 24V AC.
 The Triac controller can be operated fro either a 220V-240V, or 110V-115V AC supply and
will auto atically detect which supply voltage is connected. The controller is switched on fro
the Mini-ray Hand-tool trigger aintaining operation while the trigger is pressed. Once the
axi u operating period of 70 seconds is reached, the controller will auto atically switch to
a TIME OUT ode indicated by the green ‘ON’ LED going OFF. Further action of the Hand-
tool is inhibited until the TIMEOUT period of 2 seconds as lapsed. After the 2 seconds
lapsed, 70 seconds continuous operation again is possible, within the 70 secs operating that
ti e the trigger can be released and pressed without any delay to the operation of the la p
on the gun.

IR1759-MK5-AT3130-EDCONT MINIRAY
TE Connectivity - Aerospace, Defence & Marine /// Application Tooling
Page 9 of 36
2.3 System Description continued The IR1759-MK5 MINIRAY Hand Too
The ains supply to the controller is connected through a standard, (IEC) ains socket on the rear
panel. This socket has an integral ON/OFF switch (Fig1). Both live and neutral lines are fused
protected at the connector.
Fig1 Fig 2 Fig 3
MINIRAY Hand Too Connector –
The output connection is a ale 6-pin socket on the rear panel. Fig 2
The input connection is a 6-pin ‘fe ale’ plug at the end of the supply lead. The plug is fitted with a
locking ring and is connected to the output socket. As shown in Fig 3
Note: IR1759-MK5-AT3130-EDCONT shou d not be connected to other Contro ers except the
one supp ied
.
CAUTION
To avoid burns, the front ref ector shou d not be touched when the too is in

IR1759-MK5-AT3130-EDCONT MINIRAY
TE Connectivity - Aerospace, Defence & Marine /// Application Tooling
Page 10 of 36
2.3 System Description continued ED-7-Cont-230+110V
Mains ON ED
ON/OFF
MAIN POWER FUSES
MAINS INPUT
HEAT GUN CONNECTION
AMP ON ED

IR1759-MK5-AT3130-EDCONT MINIRAY
TE Connectivity - Aerospace, Defence & Marine /// Application Tooling
Page 11 of 36
3. Safety
“READ THESE INSTRUCTIONS”
WARNING: THIS PRODUCT IS A SOURCE OF VERY HIGH TEMPERATURE HEAT PRODUCED
BY TUNGSTEN HALOGEN LAMP. AS WITH ANY ELECTRICAL EQUIPMENT, WHEN USING THIS
HEATING TOOL, ALWAYS FOLLOW SAFETY PRECAUTIONS TO REDUCE THE RISK OF FIRE,
ELECTRIC SHOCK OR PERSONAL INJURY.
1. Read and understand this instruction anual before using MINIRAY tool.
2. Do not expose heat tool to water and oisture including but not li ited to rain and hu id
environ ents. Store indoors. Connect to grounded outlet only. Do not defeat this protection
by using adapters or odifying the plug.
3. To extend the la p life after using, run heat tool on cool for 1 to 2 inutes before turning-off.
Never store product whilst hot.
4. Turn-off all controls before unplugging.
5. Unplug heat tool before perfor ing any repair, servicing and when not in use.
6. Use heat tool on adequately rated circuits to avoid overheating of electrical syste .
7. Do not use with da aged cored or plug. If equip ent is not working as it should, has been
dropped, da aged, left outdoors, or dropped into water, return it to a service centre.
8. Do not pull or carry by cord, use cord as a handle, close a door on cord, or pull cord around
sharp edges or corners. Do not run equip ent over cord. Keep cord away fro heated
surfaces.
9. Do not unplug by pulling on cord. To unplug grasp the plug, not the cord.
10. When an extension cord is used, it ust be ini u 14-guage, 3-wire grounded cord rated
for outdoor use.
11. Use heat gun in a well-ventilated area. Do not run when co bustible aterials, vapours or
fu es are present.
12. Do not leave heat tool when plugged in. Do not leave heat tool in a running condition
unattended.
13. Do not handle plug or heat tool with wet hands.
14. Do not touch the nozzle opening, shield, or attach ents as high te perature and extre e
heat are generated at those areas. Keep your hands and body out of the hot air strea . We
reco end you wear safety glasses and protective gloves.
15. Do not use heat gun in presence of children. Do not allow to be used as a toy. Do not store
within reach of children. Keep the heat tool in a safe, dry environ ent.
16. Do not heat che icals that will ignite and /or release har ful vapours.
17. Use only as described in this anual. Use only anufacturer’s reco ended attach ents.
18. All service and/or repair work be perfor ed by qualified personnel.
3.1 Important Safety Instructions
UL 499

IR1759-MK5-AT3130-EDCONT MINIRAY
TE Connectivity - Aerospace, Defence & Marine /// Application Tooling
Page 12 of 36
Read A Instructions before Using (This Equipment) To reduce the risk of fire, e ectric shock,
or injury.
DANGER
 The MINIRAY Controllers are connected directly to the AC ains electricity supply.
Before starting any electrical aintenance or repair, always turn off the equip ent and ensure
itis co pletely disconnected fro the ains supply.
 Do not open the case of the MINIRAY Controller or Hand Tool whilst the equip ent is
connected to the ains supply. The MINIRAY equip ent ust be connected to an earth
ground power supply, which ust be protected by a 30 A residual current device.
 The MINIRAY equip ent ust not be hard-wired to a ains supply.
 Use only specified fuse types and ratings.
 Power connections for the tool ust confor to local standards and regulations
 Potentially hazardous voltages will be exposed if the equip ent covers are re oved while it is
powered or if any of the cables are da aged. Do not use the equip ent if the cables are
da aged or any of the external panels are re oved or exposed in any way.
CAUTION!
Note: Risk of burning upon contact with hot parts.
Care ust be taken not to touch any exposed hot etallic surfaces of the tool or product. Special
care ust also be taken whilst handling product i ediately after installation.
It is reco ended that protective clothing and gloves are used when operating this tool.
3.2 E ectrica Safety
3.3
Hot Surfaces Safety

IR1759-MK5-AT3130-EDCONT MINIRAY
TE Connectivity - Aerospace, Defence & Marine /// Application Tooling
Page 13 of 36
Eye protection ust be used when using this tool. Safety glasses should be worn when operating this
tool, to provide eye protection against hot debris, dust, etc.
Distance to Face > 300mm/12” When operating IR1759 MK5
 Never look directly at the la p when it is energised.
 Ensure that the optical filter and optical block asse bly are in good condition and have been
correctly fitted.
When used exactly as instructed in this anual, the MINIRAY equip ent presents no hazard to the
user.
As with all electrical equip ent, the IR1759-MK5 MINIRAY Hand Tool and Controllers ust be
operated properly. Carefully read and observe all the instructions and warnings in this anual.
Incorrect use of the IR1759-MK5 MINIRAY equip ent can cause serious injury. This equip ent ust
be operated and aintained only by fully trained and qualified personnel.
Failure to follow the anufacturer’s instructions ay void the warranty of this equip ent.
The IR1759-MK5 MINIRAY equip ent ust be operated in accordance with safe working practices
and local safety codes and regulations.
Do not use the IR1759-MK5 MINIRAY equip ent for any purpose other than its intended function.
Do not use the equip ent on or near fuelled aircraft or in a potentially explosive environ ent.
A fire ay arise if the tool is not used with care. Parts of the MINIRAY Hand Tool get hot during use.
Special care ust be taken to avoid heating aterials other than the pieces being worked on.
The MINIRAY Hand Tool should be used in a well-ventilated area, never use the tool near solids,
liquids or gases that burn easily.
Be sure that the MINIRAY Hand Tool is not placed on or near fla able aterials between uses.
3.4 Eye Protection
and Optica Radiation Hazard
3.5 Genera Safety Instructions
-
MINIRAY equipment

IR1759-MK5-AT3130-EDCONT MINIRAY
TE Connectivity - Aerospace, Defence & Marine /// Application Tooling
Page 14 of 36
Rating information of contro er,/Mode seria number/ Manufacturer’s address.
Emergency Stop
The equip ent has no separate e ergency stop syste . Use:
 The ON/OFF switch (Fig page 9) on the rear panel.
 Or re oving the power lead fro the ains supply can be used to disconnect the equip ent
fro the ains supply.
.
MINIRAY Hand Too Supp y Cab e
The cable between the Controller and the MINIRAY Hand Tool carries supply and signal voltages
and should not be disconnected whilst the controller is switched on.
3.6 Standard E ectrica Rating Labe
/Operating Equipment Safety

IR1759-MK5-AT3130-EDCONT MINIRAY
TE Connectivity - Aerospace, Defence & Marine /// Application Tooling
Page 15 of 36
4. Insta ation
Unpacking
Remove any packaging and inspect the IR1759-MK5 MINIRAY Heat Too for any damage. Check
that a items have been supp ied.
Report any damaged parts or missing items to your supp ier.
Retain a packing materia s. These wi be required if you need to return the item for repair.
Location/Positioning
The IR1759-MK5 MINIRAY Heat Too is designed to be insta ed and operated in an industria
environment. However, it shou d not be used near exp osive or f ammab e materia s or in a ocation
where it wou d be subject to moisture or excessive dust.
Parts of the Mini-ray Hand too get hot during use. Specia care must be taken to avoid heating ma-
teria s other than the pieces being worked on.
The too has an IP1.1rating.The mini ray too is designed for areas free from inf ammab e
so ids, iquids and gases.
 The MINIRAY System shou d be ocated on a bench with a eve firm surface with sufficient
c earance must be eft at the rear of the unit, for connection to the mains supp y and the
MINIRAY Hand Too . Contro ers are supp ied with a 2.5m mains ead and Hand Too with a
3.1m contro ead
 Mains e ectrica eads shou d be routed to he p prevent damage or entang ement.
 Work in areas with good ighting.
 Never use the too near so ids, iquids or gases that burn easi y.
 The too sha be maintained we .
E ectrica connections. Ref photo page 10.The ini-ray syste ust be installed in accordance
with established safe working practices. Incorrect use can cause injury.
Installation require ents ust confor to local standards and regulations
WARNING!
Breathing difficu ties / suffocation due to hazardous fumes.
Depending on the product, har ful fu es can be produced during the shrinking
and soldering procedure.
 Pay attention to the product's safety data sheet.
 The working area should be well-ventilated.
 If necessary, install an air extraction syste .
The Mini –Controller is a Class I tool. This controller is designed to operate fro a 230V±10% 50Hz
ains and 110v 60hz ains
For exa ple:ED-7-CONT-230/110V & -MK5.
The Mini Ray Syste is supplied with an appropriate power lead / plug at one end and an IEC
connector at the other.
If this ains lead is lost at any ti e it should only be replaced with a CE / UL approved ains power
supply cord.
The ains supply to the equip ent ust be protected by a 30 A residual current device
4.1 Insta ation and Set
-
Up

IR1759-MK5-AT3130-EDCONT MINIRAY
TE Connectivity - Aerospace, Defence & Marine /// Application Tooling
Page 16 of 36
Pre-Insta ation Checks
1. Ensure the input supply switch on the Controller is switched OFF.
2. Ensure the correct AT-XXXX fixture is fitted to the MINIRAY Hand Tool (See “Fitting an ATXXXX
Fixture” Page 17.)
3. Connect the MINIRAY Hand Tool to the Controller and secure the locking ring.
4. Connect the ains supply cable to the Control
5. Plug the ains supply cable into the electricity supply socket.
Se ecting the Hand Too Aperture
Two MINIRAY Hand Tool types are available the difference between odels is the aperture size:
• IR-1759 - Standard
• IR-3104 - Large
A kit (AE-897) is available to convert between standard and large aperture sizes.
The kit contains the relevant optical block, inner reflector, optical filter and locking ring.
See Pg. 30 Spare Parts and Accessories for ordering infor ation.
4.1 Insta ation and Set
-
Up
continued

IR1759-MK5-AT3130-EDCONT MINIRAY
TE Connectivity - Aerospace, Defence & Marine /// Application Tooling
Page 17 of 36
The equip ent ay be hot. Allow the MINIRAY Hand Tool fan to run until the aperture asse bly is
cool.
The procedure for changing the aperture is the sa e whichever kit is being fitted:
1. Switch OFF the Controller and disconnect it fro the ains supply.
2. Unplug the MINIRAY Hand Tool control cable fro the Controller.
3. Place the MINIRAY Hand Tool on its side with the trigger and lens to the left.
4. Re ove the two body fixing screws and separate the two halves of the Hand Tool. Fig 3 page 8
5. Re ove the optical block and optical filter asse bly taking care not to touch the surface of
the filter. Then re ove the inner reflector.
Do not touch the lamp
6. If you accidentally touch any of these parts you ust clean the with a soft clean cotton
cloth dipped in isopropyl alcohol.
7. Fit the required parts.
The lens asse bly can only be positioned at 90º incre ents, so ake sure it is fully engaged
before trying to reasse ble the tool.
8. Replace the top half of the tool, ensure that no wires are trapped, and re-fasten the two ain
screws.
4.2
Changing the Aperture

IR1759-MK5-AT3130-EDCONT MINIRAY
TE Connectivity - Aerospace, Defence & Marine /// Application Tooling
Page 18 of 36
Fitting an Aperture Kit to Change Size
Fitting an AT-XXXX Fixture
The MINIRAY equip ent can be used to install a variety of TE’s SolderSleeve
®
ter ination products.
In order to, ensure correct positioning of the product in the heating zone, a range of fixtures are
available.
Each fixture attaches to the front of the MINIRAY Hand Tool.
The available fixtures are shown in the following illustrations
AT 3130 Standard V Block
AT 3131 Solder-tact Block

IR1759-MK5-AT3130-EDCONT MINIRAY
TE Connectivity - Aerospace, Defence & Marine /// Application Tooling
Page 19 of 36
AT 3132 V Block with Cla p
AT 3132 Mk31 V Block with Cla p & 5 Wide Mask

IR1759-MK5-AT3130-EDCONT MINIRAY
TE Connectivity - Aerospace, Defence & Marine /// Application Tooling
Page 20 of 36
AT 3134 Standard V Block (Large Aperture)
AT 3147 V Block with Cla p (Large Aperture)